Proximity systems eric de zoeten

,7;www.infotronix-cws.com
Proximity Systems

InfoTronix Presenters
 Eric de Zoeten
 Engineering/General
Manger
 20 years engineering
experience in mining
 15 years coal
 5 years hardrock
 Peter O’Donnell
 Hardware/Software
Engineer
 7 years engineering
experience in mining
 TÜV Certified
Functional Safety
Engineer

Barminco Presenter
 Peter Nicholls
 Group EHS&T Manager
Barminco
 25 years experience in
mining
 Project Manager for
Proximity System Trial
 Tindals Mine, Coolgardie

Our Objective…

Proximity Detection Systems –
What we will cover
 Why proximity
 Critical proximity
system requirements
 Proximity technology
overview
 Focus on close
proximity systems
 Booyco Collision
Warning System
 Practical challenges &
lessons learnt
 Functional safety
challenges
 Industry trials

Why are proximity systems
needed?
 Additional safety for personnel
 Is becoming an industry expectation
 Reduce downtime due to injuries
 Reduce damage to equipment

Our critical requirements for
proximity systems
 Coverage stability
 Coverage repeatability
 Coverage distance
 Blind spot coverage &
warning
 Minimise unnecessary &
false alarms
 Ease of use
 Ease of maintenance
& support
 Ease of installation
 Ease of integration
with other systems
 Compatibility with
electro-explosive
devices

Some proximity technologies…
 Microwave radar
 Ultrasonic radar
 RFID tags
 VLF magnet field
 Laser range finders
 Mesh networks
 Video
 GPS
 Thermal imaging

Close Proximity

The most challenging problem is
to detect a person
in a dangerous zone
How do we do it
reliably?

One approach to
Close Proximity…
RFID (VHF & UHF)
Tags

RFID Proximity
 In our opinion:
The warning zone is less stable due to
the uneven propagation of radio waves
in the VHF & UHF bands, particularly
underground
The warning zone depends on a miner’s
position, environment, presence of other
equipment, cables, rails etc.

So unfortunately…
RFID does not provide a
Stable Warning Zone
for close proximity!

A better solution for
Close Proximity…
Very Low Frequency (VLF)
Magnetic Fields

VLF Magnetic Field
 Uses very long wavelength (>30km)
signals
 Creates very stable collision detection
zone
 Is not affected by objects or even the earth
 Does not suffer from radio-wave
propagation issues like VHF/UHF

Thus…
VLF provides a
Stable Warning Zone
for close proximity!

Introduction to the
Booyco
Collision Warning System

How it works…

Booyco System
 Combines the benefits of VLFs stable and
repeatable collision warning zone for close
proximity, with UHF long range detection.
 Complete package covering personnel,
machinery, and vehicles as well as danger
area access control.

Booyco System - Key features
 Coverage stability
 Coverage
repeatability
 Highly stable and
repeatable zones via
VLF technology
 Blind spot coverage &
warning
 Minimise false &
unnecessary alarms
 Full coverage around
vehicle/machinery
 Adjustable warning
and danger zones to
customise each
application

 Coverage distance
 Long Range UHF
detection
 Tracking & Logging  Localised logging with
network capability to
offload to centralised
database
 Close Proximity VLF
detection for people
&

 Ease of use  Simple alarming and
alerting – minimal
training required
 Ease of maintenance
& support
 Ease of installation
 Designed as simple
bolt-on modification
for any vehicle, easy
swap out of parts

 Ease of integration with
other systems
 Tracking and logging
connects to standard
Ethernet/WiFi networks.
Simple voltage free
contact interlocks for
machinery integration.
 Compatibility with Electro-
Explosive Devices
 OEM declaration of
compatibility with EED
health & safety
recommendations.
Verified by calculation &
testing.

Booyco System – Evolution
 Anglo:
 March 2006 – CWS500 at Greenside Mapula
 May 2007 – Added 2 zone detection
 October 2007 – Final testing CWS800
 November 2007 – Approval for project rollout
 January 2008 – Roll-out begins at Greenside,
Goedehoop, Kriel and New Denmark
 December 2008 – Roll-out complete
 Xstrata:
 2009~2010 – Intervention systems, Tavistock

Booyco – RSA Deployments
 Nearly 1000 systems installed to date:
456 Coal
214 Platinum
142 Base metals
25 Gold
24 Diamond

Proximity Systems
Implementation Challenges

Adapting systems to the Australian
industry - Key challenges
 Australian Certification (HAE)
 Functional Safety
 Operating & mining methods
 System Integration:
 Operating Environment
 Mechanical Packaging
 Connections
 Training

System Integration Challenges
 High ambient temperatures experienced:
43°C surface ambient temperature
46°C cab ambient temperature
Ratings of power-supplies exceeded
Ratings of all components
 Australian operating & mining methods
different to South Africa, impacting on
system operating environment

Typical temperature analysis

 Industry expectation for compatibility with
CAT connectors:
Field service spares and tooling all use CAT
 Mechanical packaging to suit plant:
Closed-cab/air-conditioned vs open-cab
RF signalling and use of externally mounted
antennas

 Suitable mounting of equipment to
machinery
 Integration into machinery wiring
looms
 Proximity system wiring looms
 Operator & maintenance training
requirements

Functional Safety in
Proximity Systems
Implementation Challenges

Defining Proximity System
Safety Functions
1. WARN the PERSON that they are in a
danger zone
2. WARN the DRIVER that a person is in
one of their danger zones
3. INTERLOCK of the MACHINERY when a
person is in a critical danger zone

Proximity SIL Requirements
 Site risk assessment should analyse
existing layers of protection to determine
required SIL for proximity functions
 Common industry expectation – SIL 2
 Proximity safety functions defined as
HIGH demand mode

IEC/AS 61508
SIL 2 Requirements
 Hardware Reliability:
10-7 ≤ PFHD ≤ 10-6
 Hardware Architecture (Type B):
HWFT SFF
0 > 90%
1 > 60%
2 < 60%

Generic Proximity Block Diagram

Diagnostic Coverage - Warning

Diagnostic Coverage - Interlock

Proximity SIL Challenges
 Machine Unit can self diagnose and
interlock from faults
 Tag Unit has limited diagnostic
opportunity, and can only warn during a
fault condition
 Tag Unit does not know if it should be
detecting a VLF field or not – that depends
on being in a danger zone or not!

 Tag Unit cannot guarantee reception of
VLF signal
 Tag Unit cannot guarantee transmission of
UHF message back to Machine Unit

 Start of shift Tag Unit proof tests are
helpful, but do not change SIL architecture
 Most likely solution is Tag Unit redundancy
 There are still further challenges…

Proximity Systems
Barminco
Industry Trials

Proximity Systems
Questions?

Proximity systems eric de zoeten

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